Mobile UVA curing system for collision and cosmetic repair of automobiles

ABSTRACT

The present invention is directed to a mobile radiation system that comprises a mobile radiation device coupled to a control unit; a radiation blocker having an adaptor opening for receiving said mobile radiation device when said mobile radiation device is in a seated position on said radiation blocker; and a mobile carrier comprising a first compartment for housing said radiation blocker, a second compartment for housing said control unit, and one or more carrier motion devices. The adaptor opening can dimensionally fit the mobile radiation device to block radiations from the mobile radiation device when said mobile radiation device is in the seated position. The mobile radiation device can produce radiation having peak radiation wavelength in a range of from 250 nm to 450 nm and can have a peak irradiation power in a range of from 0.5 W/cm 2  to 10 W/cm 2 .

CROSS REFERENCE TO RELATED APPLICATION

The present application claims the benefit of priority of U.S. provisional patent application 61/771,168, filed Mar. 1, 2013.

FIELD OF DISCLOSURE

The present disclosure is directed to a mobile radiation system. This disclosure is further directed to a mobile radiation system for curing a radiation curable coating composition to form a cured coating layer.

BACKGROUND OF DISCLOSURE

The use of radiation curable coatings becoming more common in coating industry. Such use requires a combination of radiation curable coating compositions and a radiation source. Typically, an ultraviolet (UV) source such as a UV lamp can be used for curing a UV curable coating composition applied over a substrate to form a cured coating layer. However, the radiation such as the UV radiation from the UV lamp can be harmful for operators during the use.

Therefore, needs exist for an improved radiation system.

STATEMENT OF DISCLOSURE

This invention is directed to a mobile radiation system comprising:

-   -   (a1) a mobile radiation device (1) coupled to a control unit (2)         via one or more coupling devices (3);     -   (a2) a radiation blocker (4) having an adaptor opening (5) for         receiving said mobile radiation device (1) when said mobile         radiation device is in a seated position on said radiation         blocker (4);     -   (a3) a mobile carrier (10) comprising a first compartment (11)         for housing said radiation blocker, a second compartment (12)         for housing said control unit, and one or more carrier motion         devices (13);     -   wherein said adaptor opening dimensionally fits said mobile         radiation device to block radiations from said mobile radiation         device when said mobile radiation device is in said seated         position on said radiation blocker.

This invention is further directed to a kit for a mobile radiation system, the kit comprising:

-   -   (b1) a mobile radiation device (1);     -   (b2) a control unit (2);     -   (b3) one or more coupling devices (3);     -   (b4) a radiation blocker (4) having an adaptor opening (5) for         receiving said mobile radiation device (1) in a seated position         on said radiation blocker;     -   (b5) a mobile carrier (10) comprising a first compartment (11)         for housing said radiation blocker (4), a second compartment         (12) for housing said control unit, and one or more carrier         motion devices (13);     -   wherein said mobile radiation device (1) is connectable to said         control unit (2) via said one or more coupling devices (3);     -   said adaptor opening (5) dimensionally fits said mobile         radiation device (1) to block radiations from said mobile         radiation device when said mobile radiation device is received         in said seated position on said radiation blocker.

BRIEF DESCRIPTION OF DRAWING

FIG. 1 shows schematic presentations of an example of the system. (A) The mobile radiation device is not in the seated position. (B) The mobile radiation device is in the seated position.

FIG. 2 shows schematic cross-sectional presentations of examples of the system. (A) A radiation blocker has total radiation blocking elements on all sides. (B) An example of a radiation blocker has UV blocking elements. (C) Another example of a radiation blocker has UV blocking elements.

FIG. 3 shows schematic cross-sectional presentations of examples of the system having (A) a carrier cooling fan or (B) a carrier cooling air duct.

FIG. 4 shows schematic cross-sectional presentations of examples of the system having (A) a vent fan and a shutter system; (B) a radiation reflector; and (C) a radiation area.

FIG. 5 shows a schematic presentation of an example of the system having a radiation supporting device.

DETAILED DESCRIPTION

The features and advantages of the present invention will be more readily understood, by those of ordinary skill in the art, from reading the following detailed description. It is to be appreciated that certain features of the invention, which are, for clarity, described above and below in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the invention that are, for brevity, described in the context of a single embodiment, may also be provided separately or in any sub-combination. In addition, references in the singular may also include the plural (for example, “a” and “an” may refer to one, or one or more) unless the context specifically states otherwise.

The use of numerical values in the various ranges specified in this application, unless expressly indicated otherwise, are stated as approximations as though the minimum and maximum values within the stated ranges were both proceeded by the word “about.” In this manner, slight variations above and below the stated ranges can be used to achieve substantially the same results as values within the ranges. Also, the disclosure of these ranges is intended as a continuous range including every value between the minimum and maximum values.

This disclosure is directed to a mobile radiation system. The mobile radiation device can comprise:

(a1) a mobile radiation device (1) coupled to a control unit (2) via one or more coupling devices (3);

(a2) a radiation blocker (4) having an adaptor opening (5) for receiving said mobile radiation device (1) when said mobile radiation device is in a seated position on said radiation blocker (4);

(a3) a mobile carrier (10) comprising a first compartment (11) for housing said radiation blocker, a second compartment (12) for housing said control unit, and one or more carrier motion devices (13);

wherein said adaptor opening dimensionally fits said mobile radiation device to block radiations from said mobile radiation device when said mobile radiation device is in said seated position on said radiation blocker.

The system can have the mobile radiation device not in the seated position (FIG. 1A) or with the mobile radiation device in the seated position (FIG. 1B).

The mobile radiation device can comprise a UV source such as a UV light bulb (20) such as a mercury UV lamp, a UV light-emitting diode (LED), or any other UV source that can provide the desired irradiation power at the target coating. A UV power measuring device, such as a UV POWER PUCK® FLASH, available from The EIT Instrument, Sterling, Va. 20164, USA, under respective registered trademark, can be suitable to measure UV irradiation power.

The control unit (2) can be used to adjust or control the UV irradiation power, duration of power timing, or a combination thereof. The irradiation power measured at the coating to be tested, such as the target coating or the control coating, can be adjusted by adjusting power to the mobile radiation device such as the power to the UV lamp or UV LED, the distance between the mobile radiation device and the coating to be irradiated, UV reflection assembly such configurations of radiation reflector disclosed hereafter, or a combination thereof. The control unit (2) can comprise one or more display devices (2 a-2 b), one or more adjustment devices such as dials (2 d-2 f) (FIG. 1A). The control unit can further comprise other control devices as determined necessary.

The mobile radiation device can be configured to produce radiations having peak radiation wavelength in a range of from 250 nm to 450 nm and has a peak irradiation power in a range of from 0.5 W/cm² to 10 W/cm². Different UV source can also produce UV irradiations at same or different one or more peak wavelengths. In one example, an Arc UV source can have a peak wavelength at about 315 nm or 365 nm. In another example, an LED UV source can have a peak wavelength at about 365 nm.

The radiation blocker can comprise one or more UV blocking elements (6) that permit visible radiations (21) to exit the radiation blocker while blocking UV radiations (22) from exiting said radiation blocker, when said mobile radiation device is in the seated position (FIG. 2A-2C). The UV blocking elements can be transparent, translucent, fluorescent, or a combination thereof. Examples of radiation blocker can include UV blocking glass, UV blocking plastics or other polymers, or a combination thereof. The radiation blocker can also comprise one or more total radiation blocking elements (7) that block UV radiations and visible radiations from exiting said radiation blocker. Examples of the total radiation blocking elements can include metal sheets or blocks, ceramic sheets or blocks, or any other materials that can block UV radiations and visible radiations.

One advantage of the system disclosed herein is that the UV blocking elements (6) can permit visible radiations (21) to exit the radiation blocker so an operator can visually confirm that the UV source is actually powered when the mobile radiation device is seated on the radiation blocker without being exposed to the UV irradiation.

The mobile carrier can further comprise a coupler supporting device (14) for storing and supporting said one or more coupling device (3) that couples the mobile radiation device and the control unit (FIG. 1A, FIG. 1B and FIG. 5). The mobile carrier can further comprise one or more storage compartments (15) (FIG. 1A, FIG. 1B and FIG. 5).

The mobile carrier can further comprise at least a cooling device (16) for cooling said mobile radiation device in said seated position. The cooling device can comprise a carrier cooling fan (16) (FIG. 3A), a carrier cooling air duct (16′) (FIG. 3B), or a combination thereof. The mobile carrier can further comprise one or more vents (10 a-10 b) (FIG. 1A) to provide ventilation. In one example, ambient external air (30) can be forced by the fan (16) into the carrier to cool the radiation blocker (FIG. 3A). In another example, cooled air (30′) can be provided to the carrier via the carrier cooling air duct (16′) (FIG. 3B). In another example, the carrier can comprise a combination of the cooled air and the fan to provide the cooled air (30′) into the carrier by the fan (16). The radiation blocker can have a plurality of thermal fins (7 a) for disperse heat (FIG. 3A and FIG. 3B). In another example, the carrier cam comprise the thermal fin and at least one vent (10 a) or (10 b) without the fan.

The cooling device can comprise a cooling sensing device (17) to power on the cooling device when said mobile radiation device is in the seated position. When the mobile radiation device is moved from the seated position, the cooling sensing device (17) can automatically turn off the cooling device to conserve power.

The mobile carrier can further comprise an activity sensing device (18) (FIG. 2C) coupled to the mobile radiation device and the control unit to power off the mobile radiation device if the mobile radiation device is powered and remains in the seated position for a predetermined period of time. In one example, the cooling sensing device (17) and the activity sensing device (18) can be configured into one single device (FIG. 2C) so the cooling device can be triggered to be turned on when the mobile radiation device is placed in the seated position and subsequently, the power can be turned off if the mobile radiation device remains in the seated position for a predetermined period of time.

The mobile radiation device can comprise at least one cooling vent (40) on the radiation device (FIG. 4A-4B). The mobile radiation device can further comprise at least one vent fan (41), a shutter system (43) to block the radiation of the UV source from exiting through the cooling vent (40) while allowing cooling air (42) to flow through the cooling vent, or a combination thereof.

The mobile radiation device can further comprise a radiation reflector (44) (FIG. 4B and FIG. 4C) to reflect the radiation toward a predetermined direction, such as directing to a substrate (FIG. 4C). The mobile radiation device can be configured using the radiation reflector, the opening of the mobile radiation device to adjust a radiation area (45) over a target (31) (FIG. 4C).

The one or more carrier motion devices (13) can be selected from wheels, powered wheels, rolling wheels, tracks, rails, or a combination thereof.

The mobile radiation system can further comprise a battery power source (32) for supplying power to the mobile radiation device (1), the control unit (2), or a combination thereof.

The mobile carrier can further comprise one or more radiation supporting devices (19) (FIG. 5) to position said mobile radiation device for providing radiation to a target. In one example, one of radiation supporting devices (19) can be a retractable arm so the mobile radiation device can be attached at one end. In another example, the radiation supporting device can be coupled to a computing device or other automation devices to move the mobile radiation device in a predetermined pattern, predetermined distance to a target, a range of predetermined velocity, or a combination thereof.

The aforementioned target can comprise a target coating layer (34), such as a wet coating layer over a coated area of a substrate (31) (FIG. 5). The target coating layer (34) can be formed from one or more radiation curable target coating compositions applied over the coated area of the substrate. The target coating compositions can be solvent borne or waterborne coating compositions. The target coating layer can be cured with the radiation alone or a combination of the radiation with one or more curing processes selected from thermal curing, physical drying curing, chemical curing, or a combination thereof. Thermal curing can include curing at ambient temperatures, such as temperatures in a range of from 15° C. to 50° C.; at elevated temperatures, such as temperatures in a range of from 50° C. to 350° C.; or a combination thereof. Lacquer coating compositions can be cured by drying. The term “lacquer” or “lacquer coating composition” refers a coating composition that is capable of drying by solvent evaporation to form a durable coating on a substrate.

Chemical curing can include the reactions between crosslinkable and crosslinking functional groups. Typical crosslinkable and crosslinking functional groups can include hydroxyl, thiol, isocyanate, thioisocyanate, acid or polyacid, acetoacetoxy, carboxyl, primary amine, secondary amine, epoxy, anhydride, ketimine, aldimine, or a workable combination thereof. Some other functional groups such as orthoester, orthocarbonate, or cyclic amide that can generate hydroxyl or amine groups once the ring structure is opened can also be suitable as crosslinkable functional groups.

It would be clear to one of ordinary skill in the art that certain crosslinking functional groups crosslink with certain crosslinkable functional groups. Examples of paired combinations of crosslinkable and crosslinking functional groups can include: (1) ketimine functional groups crosslinking with acetoacetoxy, epoxy, or anhydride functional groups; (2) isocyanate, thioisocyanate and melamine functional groups each crosslinking with hydroxyl, thiol, primary and secondary amine, ketimine, or aldimine functional groups; (3) epoxy functional groups crosslinking with carboxyl, primary and secondary amine, ketimine, or anhydride functional groups; (4) amine functional groups crosslinking with acetoacetoxy functional groups; (5) polyacid functional groups crosslinking with epoxy or isocyanate functional groups; and (6) anhydride functional groups generally crosslinking with epoxy and ketimine functional groups.

The irradiation curable functional groups can include ethylenically unsaturated double bonds, such as acrylic or methacrylic double bonds. Sources of UV irradiation for curing can include natural sunlight or artificial UV radiation sources. Examples of UV irradiation for curing can include, but not limited to, UV-A radiation, which falls within the wavelength range of from 320 nanometers (nm) to 400 nm; UV-B radiation, which is radiation having a wavelength falling in the range of from 280 nm to 320 nm; UV-C radiation, which is radiation having a wavelength falling in the range of from 100 nm to 280 nm; and UV-V radiation, which is radiation having a wavelength falling in the range of from 400 nm to 800 nm.

A coating composition having crosslinkable and crosslinking functional groups and the irradiation curable functional groups can be cured by a combination of the chemical curing and the irradiation curing. Such coating compositions can be referred to as a dual cure coating composition.

The substrate can be a vehicle or vehicle part.

This disclosure is further directed to a kit for a mobile radiation system. The kit can comprise:

(b1) a mobile radiation device (1);

(b2) a control unit (2);

(b3) one or more coupling devices (3);

(b4) a radiation blocker (4) having an adaptor opening (5) for receiving the mobile radiation device (1) in a seated position on the radiation blocker;

(b5) a mobile carrier (10) comprising a first compartment (11) for housing the radiation blocker (4), a second compartment (12) for housing the control unit, and one or more carrier motion devices (13);

wherein the mobile radiation device (1) is connectable to the control unit (2) via the one or more coupling devices (3);

the adaptor opening (5) dimensionally fits the mobile radiation device (1) to block radiations from the mobile radiation device when the mobile radiation device is received in the seated position on the radiation blocker.

The mobile radiation device of the kit can be configured to produce radiations having peak radiation wavelength in a range of from 250 nm to 450 nm and has a peak irradiation power in a range of from 1 W to 10 W.

The radiation blocker of the kit can comprise one or more UV blocking elements (6) that are capable of permitting visible radiations (21) to exit the radiation blocker while blocking UV radiations (22) from exiting the radiation blocker, the one or more UV blocking elements are transparent, translucent, fluorescent, or a combination thereof.

The mobile carrier of the kit can further comprise at least a cooling device (16) connectable to the mobile radiation device and the control unit for cooling the mobile radiation device, and the cooling device comprises a cooling sensing device (17) connectable to the cooling device to power on the cooling device when the mobile radiation device is received in the seated position.

The mobile carrier can further comprise an activity sensing device (18) connectable to the mobile radiation device and the control unit to power off the mobile radiation device when assembled and powered, if the mobile radiation device is powered and remains in the seated position for a predetermined period of time. 

What is claimed is:
 1. A mobile vehicle part radiation system for curing a radiation curable coating composition on a vehicle part comprising: (a1) a mobile radiation device (1) coupled to a control unit (2) via a coupling devices; (a2) a radiation blocker (4) having an adaptor opening (5) for receiving said mobile radiation device (1) when said mobile radiation device is in a seated position on said radiation blocker (4); (a3) a mobile carrier (10) comprising a first compartment (11) for housing said radiation blocker, a second compartment (12) for housing said control unit, and one or more carrier motion devices (13); (a4) a substrate having a coating of a UV radiation curable composition, said substrate comprising a vehicle part and said coating positioned at a predetermined irradiation distance from said radiation device; (a5) said radiation device adapted to produce UV radiation in a range of from 100 nm to 800 nm and a peak irradiation power at the coating sufficient to cure said coating; wherein said adaptor opening dimensionally fits said mobile radiation device to block radiations from said mobile radiation device when said mobile radiation device is in said seated position on said radiation blocker; and, wherein during curing operation said mobile radiation device is not in said seated position, is positioned at said predetermined irradiation distance and radiation cures said coating on said vehicle part.
 2. The mobile radiation system of claim 1, wherein said mobile radiation device is configured to produce radiations having peak radiation wavelength in a range of from 250 nm to 450 nm and has a peak irradiation power in a range of from 0.5 W/cm² to 10 W/cm².
 3. The mobile radiation system of claim 1, wherein said radiation blocker comprises one or more UV blocking elements (6) that permit visible radiations (21) to exit said radiation blocker while blocking UV radiations (22) from exiting said radiation blocker, when said mobile radiation device is in said seated position.
 4. The mobile radiation system of claim 3, wherein said one or more UV blocking elements are transparent, translucent, fluorescent, or a combination thereof.
 5. The mobile radiation system of claim 1, wherein said mobile carrier further comprises a coupler supporting device (14) for storing and supporting said coupling device (3) that couples said mobile radiation device and said control unit.
 6. The mobile radiation system of claim 1, wherein said mobile carrier further comprises one or more storage compartments (15).
 7. The mobile radiation system of claim 1, wherein said mobile carrier further comprises at least a cooling device (16) for cooling said mobile radiation device in said seated position.
 8. The mobile radiation system of claim 7, wherein said cooling device comprises a cooling sensing device (17) to power on the cooling device when said mobile radiation device is in said seated position.
 9. The mobile radiation system of claim 1, wherein said mobile carrier further comprises an activity sensing device (18) coupled to said mobile radiation device and said control unit to power off said mobile radiation device if said mobile radiation device is powered and remains in said seated position for a predetermined period of time.
 10. The mobile radiation system of claim 1, wherein said one or more carrier motion devices are selected from wheels, powered wheels, rolling wheels, tracks, rails, or a combination thereof.
 11. The mobile radiation system of claim 1, wherein said coating composition is a wet coating layer (30) over said vehicle part, said wet coating layer is formed from a radiation curable coating composition applied over said coated vehicle part.
 12. The mobile radiation system of claim 11, wherein said coupling device extends from said control unit a predetermined distance to said mobile radiation device.
 13. The mobile radiation system of claim 1 further comprising a battery power source (32) for supplying power to said mobile radiation device (1), said control unit (2), or a combination thereof.
 14. An automobile part curing system for curing a radiation curable coating composition applied to an automobile part to form a cured coating layer comprising: an automobile part on which a UV radiation curable coating has been applied; a radiation device comprising a housing having a top, a bottom, a height, a length, a width, a reflector positioned within said housing and a UV source positioned within said housing between said reflector and said bottom; said reflector positioned at a fixed location within said housing, extending along the length of the radiation device length, adapted and positioned to reflect UV radiation along its length and to focus radiation toward a substrate positioned in a predetermined a direction from the bottom of said radiation device; said UV source adapted to produce UV radiation in a range of from 100 nm to 800 nm and a peak irradiation power at a predetermined distance from said coating; a handle positioned on the top of said radiation device housing; a mobile carrier comprising a housing having a top, a bottom, a power supply, wheels positioned on the bottom of the carrier, a power cord extending from said power supply to said radiation device, a system control unit and a radiation blocker; said radiation blocker comprising a body having a top, bottom, sides and a cavity positioned on the top of said radiation blocker, said cavity sized and configured to receive and seat said radiation device; said radiation blocker comprising a material that substantially prevents said UV radiation from exiting said radiation blocker; said system control unit adapted to control irradiation power and duration of radiation; said automobile part positioned a predetermined distance from said radiation device; whereby irradiation of said coating forms said cured coating layer on said vehicle part. 